【Waterjet Machining Application】Waterjet machining resolves material cutting challenges in quality control, significantly boosting production efficiency!
Quality assurance and quality control are essential processes in factory production. Regardless of how long a factory has been in operation, quality checks must be performed regularly to maintain consistent quality standards. Quality control on the production line typically involves regular testing of manufactured samples, and it's crucial that these samples come from the actual production line.
By definition, there are no valid substitutes for samples; otherwise, they wouldn't be "samples." The quality control process may involve testing raw materials to verify material properties, testing manufacturing steps to ensure they are completed correctly, and inspecting finished products for compliance.
In quality control applications, samples must be physically cut to prepare them for testing. When designing these sample cutting procedures, quality control engineers face several challenges. The first is speed; since online quality inspections can hold up a production batch, samples must be produced quickly. Second, when visual inspection is required, features might not be easily visible. Finally, when preparing for quality control tests, cutting the material or samples from the production line might alter the material's integrity.
By definition, there are no valid substitutes for samples; otherwise, they wouldn't be "samples." The quality control process may involve testing raw materials to verify material properties, testing manufacturing steps to ensure they are completed correctly, and inspecting finished products for compliance.
In quality control applications, samples must be physically cut to prepare them for testing. When designing these sample cutting procedures, quality control engineers face several challenges. The first is speed; since online quality inspections can hold up a production batch, samples must be produced quickly. Second, when visual inspection is required, features might not be easily visible. Finally, when preparing for quality control tests, cutting the material or samples from the production line might alter the material's integrity.
Diverse Cutting Methods, Each with Limitations
While there are various methods for cutting samples, each presents different challenges for quality control. There are many ways to cut metals today, but each method is generally limited to certain types of metal. Traditional machining is primarily used for metal blanks, shearing for sheet metal, laser cutting for non-reflective sheet metal, and plasma cutting for thick, conductive sheet metal.
For non-metallic materials, practical cutting processes are fewer. Fiber composites produce toxic dust when cut with saws or rotary blades, and ceramics can crack or shatter, even with special wet saws. Plastic and rubber materials may melt, gum up, or emit fumes when cut with blades or lasers.
Even worse, these cutting methods often deform the material. Laser cutting creates a heat-affected zone that hardens the cut edge. Sawing or shearing can bend or deform the edges of sheet metal, and plasma cutting introduces heat that can deform thin materials. Therefore, each of these cutting technologies can affect the results of quality control.
Fortunately, there is a cutting process that works for all materials while minimizing deformation of the cut material: abrasive waterjet cutting. Waterjet cutting combines a narrow, high-pressure stream of water with abrasive particles, which are ejected through a nozzle to penetrate the object. This is a micro-erosion material removal process that cuts without generating heat or mechanical stress on the material. Since all materials are subject to erosion, waterjet cutting is generally preferred, leaving a smooth surface finish similar to sandblasting.
Waterjet cutting technology is particularly suitable for quality control applications where material integrity must be ensured, or when part integrity is crucial. However, quality control departments often cannot justify the capital investment for large waterjet cutting machines; until recently, small waterjet cutting machines were not available. Newly launched and affordable waterjet cutting machines allow quality control engineers to use this unique process to quickly cut exact material samples for in-house use.
For non-metallic materials, practical cutting processes are fewer. Fiber composites produce toxic dust when cut with saws or rotary blades, and ceramics can crack or shatter, even with special wet saws. Plastic and rubber materials may melt, gum up, or emit fumes when cut with blades or lasers.
Even worse, these cutting methods often deform the material. Laser cutting creates a heat-affected zone that hardens the cut edge. Sawing or shearing can bend or deform the edges of sheet metal, and plasma cutting introduces heat that can deform thin materials. Therefore, each of these cutting technologies can affect the results of quality control.
Fortunately, there is a cutting process that works for all materials while minimizing deformation of the cut material: abrasive waterjet cutting. Waterjet cutting combines a narrow, high-pressure stream of water with abrasive particles, which are ejected through a nozzle to penetrate the object. This is a micro-erosion material removal process that cuts without generating heat or mechanical stress on the material. Since all materials are subject to erosion, waterjet cutting is generally preferred, leaving a smooth surface finish similar to sandblasting.
Waterjet cutting technology is particularly suitable for quality control applications where material integrity must be ensured, or when part integrity is crucial. However, quality control departments often cannot justify the capital investment for large waterjet cutting machines; until recently, small waterjet cutting machines were not available. Newly launched and affordable waterjet cutting machines allow quality control engineers to use this unique process to quickly cut exact material samples for in-house use.
Affordable waterjet cutting machines can be used for in-house quality control applications.
Integrating Waterjet into Quality Control Processes
Consider an automotive supplier performing laser welding operations to join thin steel components. Weld samples from each production line batch must be inspected to verify the integrity of the entire batch of welds. How is the weld visually inspected? During cutting, the cross-section of the weld must be cut through without distorting the integrity of the weld. Excessive heat cannot be introduced during cutting, so laser cutting, plasma cutting, or angle grinders cannot be used. Therefore, specimens are typically cut by hand with a bandsaw. Even a Tier 1 automotive supplier will hand-cut weld samples on the production line with a bandsaw for quality control.
Waterjet cutting technology is suitable for solving this problem because waterjet cutting does not heat or shear or otherwise distort the weld during cutting. The weld is preserved in its original form, allowing easy inspection of the weld cross-section.
Waterjet cutting reveals the cross-section of a laser-welded joint.
When evaluating thin stamped metal parts, quality control engineers face the challenge of preparing samples without damage. For example, an aluminum can manufacturer must inspect the tops and bottoms of aluminum cans after stamping to ensure correct ridge formation. As part of a quality control process, samples from the production line are regularly inspected. To inspect the cross-section, the can must be cut vertically in half. How can stamped thin aluminum be cut without destroying the stamped shape and ridges of the can? The answer: embed the can in epoxy. The can is embedded in epoxy, allowed to cure, and then cut with a bandsaw and the epoxy removed.
However, this time-consuming process can delay the collection of QA data, which may further delay the identification and remediation of related production defects. A faster, simpler, and more consistent solution is now available using a waterjet cutting machine. It can cut thin metal without deforming it by introducing excessive heat.
For quality control engineers at aerospace companies who must verify the material properties of raw materials, using a waterjet cutter to cut tensile test specimens is a smart choice. Hardened steel is a material produced by quenching and then tempering, and cutting it with traditional methods is very cumbersome because tools wear out quickly. Companies often outsource this work to waterjet cutting services because traditional large equipment is unaffordable in-house. Relying solely on external suppliers for critical quality control procedures can lead to schedule delays and risks. Using an affordable, small waterjet cutting machine can greatly reduce risks and allow quality management departments to control the entire production process.
However, this time-consuming process can delay the collection of QA data, which may further delay the identification and remediation of related production defects. A faster, simpler, and more consistent solution is now available using a waterjet cutting machine. It can cut thin metal without deforming it by introducing excessive heat.
For quality control engineers at aerospace companies who must verify the material properties of raw materials, using a waterjet cutter to cut tensile test specimens is a smart choice. Hardened steel is a material produced by quenching and then tempering, and cutting it with traditional methods is very cumbersome because tools wear out quickly. Companies often outsource this work to waterjet cutting services because traditional large equipment is unaffordable in-house. Relying solely on external suppliers for critical quality control procedures can lead to schedule delays and risks. Using an affordable, small waterjet cutting machine can greatly reduce risks and allow quality management departments to control the entire production process.
Cutting hardened steel tensile test specimens in-house using a waterjet cutting machine.
Accelerating New Material Development
Material testing and quality evaluation are not only for the production line. They are also part of a materials company's product development process. For example, a polyurethane material manufacturer needs to test samples of each new formulation developed to assess material quality. While waterjet cutting tensile specimens is already used, the actual cutting work can only be outsourced to waterjet cutting services. Until recently, waterjet cutting equipment was large and expensive, only suitable for high-volume production environments. The R&D department of a small materials company simply couldn't afford one. Additionally, before samples were returned, the lead time was at least 2-3 weeks, which not only severely delayed the entire testing process but also bogged down subsequent arrangements for repeated verification. With the advent of small waterjet cutting machines, material manufacturers of any size can now perform in-house material sample cutting, shortening validation cycles, accelerating product development, while maintaining full control over the QA/QC process.
Revolutionary Waterjet Technology for Quality Control
Waterjet cutting has always been associated with manufacturing processes, and its advantages in quality control are evident. Unlike test samples processed with lasers, plasma, or traditional machining, waterjet cutting provides clean, readily inspectable samples while preserving the original characteristics of the material, such as welds and shapes like cans. And now, waterjet cutting machines are smaller, more affordable, and easier to use. Therefore, quality control engineers can operate them in-house at any time for production, testing, or development. This greatly accelerates testing cycles while improving the integrity of quality control data.
Material testing and quality evaluation are not only for the production line. They are also part of a materials company's product development process. For example, a polyurethane material manufacturer needs to test samples of each new formulation developed to assess material quality. While waterjet cutting tensile specimens is already used, the actual cutting work can only be outsourced to waterjet cutting services. Until recently, waterjet cutting equipment was large and expensive, only suitable for high-volume production environments. The R&D department of a small materials company simply couldn't afford one. Additionally, before samples were returned, the lead time was at least 2-3 weeks, which not only severely delayed the entire testing process but also bogged down subsequent arrangements for repeated verification. With the advent of small waterjet cutting machines, material manufacturers of any size can now perform in-house material sample cutting, shortening validation cycles, accelerating product development, while maintaining full control over the QA/QC process.
Revolutionary Waterjet Technology for Quality Control
Waterjet cutting has always been associated with manufacturing processes, and its advantages in quality control are evident. Unlike test samples processed with lasers, plasma, or traditional machining, waterjet cutting provides clean, readily inspectable samples while preserving the original characteristics of the material, such as welds and shapes like cans. And now, waterjet cutting machines are smaller, more affordable, and easier to use. Therefore, quality control engineers can operate them in-house at any time for production, testing, or development. This greatly accelerates testing cycles while improving the integrity of quality control data.
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